Time and temperature additive scheduling

ABSTRACT

A sublimation donor has a first fabric enhancer that sublimates from the donor above a first temperature and follow by a second fabric enhancer that sublimates from the donor above a second temperature. Both the first and second temperatures used are above 260° F. and the second temperature is at least 10° F. higher than the first temperature. Upon sublimation under a single pass processing unit, first and second catalysts triggers the first and second fabric enhancers to sublimate at the first and second temperatures, respectively.

This application is a continuation of U.S. application Ser. No.11/690,003, filed Mar. 22, 2007 which claims priority to U.S.provisional application Ser. No. 60/785,527 filed Mar. 24, 2006.

FIELD OF THE INVENTION

The field of the invention is in sublimation of textile products.

BACKGROUND

Conventional methods for textile manufacturing is complex due to thewide variety of steps, process, substrates, and machineries involved.Starting from processing raw natural or manufactured fibers intofinished fabric, textile operations can be broadly classified into twosteps: dry processing and wet processing. Dry processing involves manysteps, but they are mainly mechanical processes and they tend no toproduce as much environmental waste as wet processing. Wet processinginvolves not only mechanical processes, but also chemical heavypreparation that can create significant environmental impact.

During traditional wet processing, fabric has to be cleaned and preparedthat often involves scouring, bleaching, heat setting, texturing and soforth. Once prepared, the fabric is ready for printing and dyeing andoften followed by a finishing step in which the fabric is conditionedwith different chemicals, such as fabric softeners, anti-microbialagents, stain-release agents and so forth, for more effectivecharacteristics and performance.

There are at least two major problems associated with the traditionalwet processing method. First, many individual steps are required underseparate operations, which means multiple machineries need to be used.The different machines and steps often require the textile to travelfrom site to site or even from country to country for assembly into thefinal product.

Attempts have been made to save time and labor costs by consolidating afew chemical process into one step. U.S. Pat. No. 6,251,210 (to Bullock)describes a method to finishing a fabric with both stain resistant,water repellant, and anti-microbial agents in one setting. U.S. Pat. No.7,037,346 (to Cates et al.) also describes a textile substrate thatcontains multi-finishes in the fluorochemical group. Once both cationicand repellant properties is applied to the fabric, the fabric then isdipped into an aqueous solution before being moved to a printing stationfor printing and dyeing. The drawback of these patents is that theystill do not solve the problem of consolidating multiple processingsteps into one single, continuous process. Again, the multipleprocessing steps creates significant cost in time and labor but alsocreates the second more serious problem, pollution.

The use of catalysts and chemicals during traditional wet processingoften generates a panoply of environmental waste ranging from air towater pollutants. Efforts have been made in which a single-passsublimation machine is used that consolidates many of the processingsteps into one continuous process. However, by failing to identifycommercially viable non-polluting catalysts, the single-pass processstill faces a hurdle for successful commercial application.

Various efforts also have been attempted in generating non pollutingcatalysts such as shown in U.S. Pat. No. 7,101,921 (to Edwards) andKorean Pat. No: KR2050328A (to Cha et al.), but these catalysts stillwas unable to provide for textile preparation in one combinedsingle-pass machinery. The challenge is to combine a single-pass machinethat incorporates all the wet processing steps into one continuousprocess with non-polluting catalysts that limits labor costs, time, andpollution.

Thus, it would be desirable to have textile that is pre-treated and beactivated and conditioned in a continuous process with more efficiencyand less pollution. It would also be desirable to have a fabric that canenter into a machine as roll goods or cut piece to be prepared, finishedand permanently dyed and printed in less than one continuous minute andbe ready for immediate cutting or sewing.

SUMMARY OF THE INVENTION

The present invention provides apparatus, systems and methods in which asublimation donor comprises different fabric enhancer that are activatedat different temperatures.

In preferred embodiments, sublimation donor has a first fabric enhancerthat sublimates from the donor above a first temperature and follow by asecond fabric enhancer that sublimates from the donor above a secondtemperature. Both the first and second temperatures used are above 260°F. and the second temperature is at least 10° F. higher than the firsttemperature.

In another preferred embodiments, there is first and second catalyststhat trigger the first and second fabric enhancers to sublimate at thefirst and second temperatures, respectively. The catalysts is selectedfrom the group consisting of olefins, sulfonium compounds, polyanilinecompounds, and tetra-amido macrocyclic ligands. Fabric enhancers caninclude finishing and conditioning agents.

In yet another preferred embodiments, one of the fabric enhancer is ableach, anti-microbial substance or, stain release agent. The first andsecond temperatures differ by at least 20° F. and 30° F. It is alsocontemplated that the donor has first and second different colorants,each of which sublimates from the donor at a temperature of at least385° F.

In an alternative preferred embodiment, a fabric produced using thesublimation donor that sublimates a first and a second fabric enhancerat first and second temperate. Furthermore, the fabric also containvisibly detectable amounts of both first and second colorants, thefabric further contains a detectable amount of the first fabricenhancer, and the first fabric enhancer is selected from a bleach, anantimicrobial substance, and a stain release agent.

In preferred embodiments, the first and second colorants are sublimatedonto the fabric in a continuous disposition. The fabric contains adetectable amount of the second fabric enhancer, and each of the firstand second fabric enhancers is selected from a bleach, an antimicrobialsubstance, and a stain release agent.

In yet another preferred embodiment, a receiver comprises a first fabricenhancer that activates to the receiver above a first temperature, and asecond fabric enhancer that activates to the receiver above a secondtemperature. The first and second temperatures are each above 260° F.,and the second temperature is at least 10° F. higher than the firsttemperature.

In another preferred embodiment, a method of operating a sublimationprinting device comprises: providing a donor that accepts a first andsecond enhancer; juxtaposing at least a portion of the donor with atleast a portion of a receiver; and then heating the donor fromtemperature (T1) to temperature (T2) for a period of time (S), definedby Q=M·(T1−T2)·S. Q is energy in calories needed to sublimate the donorand M is the mass in grams per cm² of the receiver. The relationship issuch that longer sublimation time and temperature is needed depending onthe mass of the receiver and the heat source capabilities.

In yet another preferred embodiment, a method of operating a sublimationprinting device is provided by first providing a donor that has a firstfabric enhancer that sublimates from the donor above a first temperatureand follow by a second fabric enhancer that sublimates from the donorabove a second temperature, juxtaposing at least a portion of the donorwith at least a portion of a receiver; and then heating the donor from260° F. to 385° F. over a time period of at least 0.35 seconds, 0.5seconds or 0.7 seconds.

Various objects, features, aspects and advantages of the presentinvention will become more apparent from the following detaileddescription of preferred embodiments of the invention, along with theaccompanying drawings in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a schematic of processing equipment according to the teachesherein.

FIG. 2 is a chart illustrating the time and temperature release of thechemical elements used in Example 2.

DETAILED DESCRIPTION

The inventor discovered that donor carrier treated with a variety ofnative elements, such as non-polluting catalysts, can be activated oneelement at a time via sublimation following a discreet temperature witha predetermined timed schedule. Preferably, a treated donor, unlike thestandard donor that comes with only process dyes, is primed with avariety of different chemical elements, such as bleaching agents, fabricenhancers and a variety of other fabric altering agents.

The present inventive subject matters uses a single source of energy totrigger a succession of chemical events stacked on the treated donorcarrier. The sublimation process is controlled via a predetermined timeand discreet temperature schedule. The combination of the treated donorand the control of time and temperature allows the single-pass processsublimation to be carried out in the most efficient, cost-effective waythat also substantially reduced pollution.

I. Treated Donor

In general, a donor has to be treated with either special dyes or othertypes of chemical agents to sublimate onto a receiver. The chemicalagents used and defined herein in the broadest possible sense to includechemicals, agents and materials that can prepare or condition thesurface of the fabric when applied upon exposure to moisture and certaintemperatures.

Specially, donor can be treated with a “preparation agent” or“preparation agents.” Preparation agent or agents are to clean orprepare the fabric prior to finishing and printing and dyeing. Normally,preparation agents are applied first during the sublimation process.Preparation agent can be selected from known materials used in theindustry to prepare the fabric, for example, the preferred preparationincludes bleaching. However, preparation agents also includes agents orchemical compositions that cause heat-setting, desizing, singeing,scouring, and even mercerization for cotton.

In preferred embodiments, a donor proceeds to a finishing step.Finishing step of the fabric includes any operation that improves theappearance and/or usefulness of fabric. While finishing encompassesseveral mechanical process, such as texturing or napping, it iscontemplated that the present finishing prefers to be a chemicalprocess, which utilizes fabric enhancers. The terms “fabric enhancer”and “fabric enhancers” used herein are defined in the broadest possiblesense to include chemicals, agents and materials that can treat, finishor condition the surface of the fabric when applied upon exposure tomoisture and certain temperatures. Fabric enhancer can be selected fromknown materials used in the industry to enhance the performance, such asfabric softener, permanent press agents, anti-microbial agents,stain-repellent agents, adhesive agents, water-resistant agents,fire-resistant agents, antistatic agents, stiffeners, anti-creasingagents, deodorants, moth resisting agents, oil repellants, rustpreventatives, and shrinkage controllers. It is also contemplated thatfabric enhancers include conditioning agents, pharmaceuticals, andnutraceuticals agents that provide nutritional values through thecatalytic conversion of the fabric surface into the wearer's skin.Skin-absorbent agents can also be used in which specific chemicals canbe padded on a fabric and deliver to the skin with each wash.

It is preferred that the chemical finishing using fabric enhancers bedone on a single, continuous finishing process unit or range along withthe step of preparing the fabric. Depending on the desiredcharacteristics of the end products, some fabric may be finished morethan others. It is important to note that there is no set recipe for thechemical process used for any fabric substrate. Different fabricenhancers are contemplated to be activated upon a given temperature fora given time period.

Other chemical agents and additives include, but are not limited to,builders, surfactants, enzymes, bleach activators, bleach boosters,bleaches, alkalinity sources, antibacterial agents, colorants, perfumes,pro-perfumes, finishing aids, lime soap dispersants, composition malodorcontrol agents, odor neutralizers, polymeric dye transfer inhibitingagents, crystal growth inhibitors, photobleaches, heavy metal ionsequestrants, anti-tarnishing agents, anti-microbial agents,anti-oxidants, anti-redeposition agents, electrolytes, pH modifiers,thickeners, abrasives, divalent or trivalent ions, metal ion salts,enzyme stabilizers, corrosion inhibitors, diamines or polyamines and/ortheir alkoxylates, suds stabilizing polymers, solvents, process aids,fabric softening agents, optical brighteners, hydrotropes, suds or foamsuppressors, suds or foam boosters, fabric softeners, antistatic agents,dye fixatives, dye abrasion inhibitors, anti-crocking agents, wrinklereduction agents, wrinkle resistance agents, soil release polymers, soilrepellency agents, sunscreen agents, anti-fade agents, water resistantagents, fire retardant agents and mixtures thereof.

The catalysts used to activate the chemical elements are preferablyenvironmental friendly catalysts in which they have little if any toxicsubstances. Some preferred catalysts include olefins, sulfoniumcompounds, polyaniline compounds, and tetra-amido macrocyclic ligands.However, it is contemplated that any environmental friend or “green”catalysts can be used to activate the chemical native elements on thefabric.

In preferred embodiments, printing and dyeing fabric is the final stepin a continuous sublimation process. Upon heating, dyes and colorantswill react and form an affinity with certain fiber surfaces. Withdye-based formulation, the heating step of the process causes the dyeparticles to change from a solid state to a gas state. In a gas state,the dye particles enters into a tissue, such as polyester fabric fibers,to set the dye. The heat opens pores in the polyester fiber allowing thegas to enter in a molecular form which is more highly reflective andcapable of producing more brilliant color on the substrate. Following acooling stage, the dye particles are trapped internally in the polyesterfiber, possibly reverting back to their solid state or at least beingfixed in the solid substrate fibers. So when white fabric is placedagainst printed donor material and heat is applied to the material, themolecules are excited and transformed into a gas state. As heated dyemolecules now penetrates the heated fabric, the dye particles permeatesthe fabric and become part of the fabric filament. Now the dye ladenmolecules are a permanent part of the interior of the fabric and are notaffected by normal washing or bleaching.

It should also be appreciated that the terms “dye”, “dyes”, “colorant”and “colorants” are used in the broadest possible sense to include inks,and indeed any chemical composition that can be transferred to areceiving material to color that material. Thus, the terms “dye”,“dyes”, “colorant” and “colorants” include chemical compositions thatcan change color depending upon temperature or other conditions, andeven chemical compositions that are colorless when applied, but turncolor upon exposure to moisture, or high temperature.

It is further contemplated that a receiver can be used directly to reactwith different chemical agents. Device can spray or inject differentchemical agents directly onto the receiver. Once the receiver receivesgoes through a time and temperature schedule, the chemical agents arereleased and the catalytic phase occurs directly on the receiver. Thiscan even apply to special dyes which is injected into the receive andreacts to a direct or indirect heat source for a set amount of period.Under a heat source, the dyes react and activate onto the receiver andstay the same. This preferably is more applicable in the area of carpetsand rugs where sublimating donor material does not always yield the bestresults. By directly activating the receiver, chemical agents and dyescan be set more effectively.

II. Implementation

In an exemplary configuration as depicted in FIG. 1, process unit 100generally includes heating portion 10 and work table 20. Positioned onthe machine is a continuous work piece 25 comprising: donor material 30with corresponding donor feed roll 32 and donor take up roll 34; tissue40 with corresponding tissue feed roll 42 and tissue take up roll 44;and receiver 50 with corresponding receiver feed roll 52 and receivertake up roll 54.

In preferred embodiments, process unit 100 can handle preparing,printing and dyeing and finishing the textile in one single press. Theadvantage of such process is that the finishing steps can be achievedbefore the dyeing and printing steps.

Preferably, donor material 30 can be selected from known donor papers,or other materials used in the industry. It is contemplated that donormaterial 30 is conditioned by a plurality of preparation agents, fabricenhancer and dyes. The donor material preferably is a thin sheet thathas a surface in which the preparation agents, the fabric enhancers anddyes can be temporarily held. Upon heating the donor material for acertain amount of time frame and at a certain temperature, a catalyticmechanism is triggered into releasing the preparation agents, the fabricenhancers and dyes onto the fabric.

Additionally, a use of a nonpolluting catalysts, such as TAML®, forIron-Tetra Amido Macrocyclic Ligand, a compound discovered at theCarnegie Mellon's Institute for Green Oxidation, can be added to triggerthe release mechanism for dispersion of the preparation agents, thefabric enhancers and the dyes to work faster and more safely. Othernonpolluting catalysts such as the macrocylic tetraamides described incolumn 4, lines 6-24, U.S. Pat. No. 6,100,394 (to Collins et al.), arealso contemplated. This reference is incorporated herein by reference inits entirety. Where a definition or use of a term in an incorporatedreference is inconsistent or contrary to the definition of that termprovided herein, the definition of that term provided herein applies andthe definition of that term in the reference does not apply.

Donor material 30 then goes through a heating portion 16 forsublimation. The heating portion 16 generally includes a rotary primaryheating element 12, a fixed heating element 14, and a heat conductiveweb 16. The web 16 is positioned by positioners 16A-16E. The rotationspeed, configuration and dimensions of the heating portion 16 determinethe dwell time of sublimating heat upon the sandwiched work piece ofdonor materials 30, receiver 50 and tissue 40.

Thus, it is contemplated that the range of heat sufficient to sublimatethe whole process from preparing the fabric to finishing the fabric andfinally to printing and dyeing the fabric would be applied from at leastone side of the receiver for at least for at least 5 seconds, morepreferably at least 10 seconds, 20 seconds, 40 seconds, 60 seconds, andmost preferably at 80 seconds. However, it is contemplated that anyheating from 5 seconds to 30 minutes is the anticipated acceptablerange.

It is also contemplated that the range of sublimation temperature forthe whole process starts from preferably no less than 260° F., andpreferably no more than 390° F.

However, the temperature and time window to sublimate depends on thecharacteristics of the receiver. The relationship between time andtemperature schedule as to the calories needed for a particular sizereceiver is as follows:

Q=M·(T1−T2)·S.

M defines mass which is measures in grams per cm² of the receiver. T1defines a first temperature and T2 defines a second temperature. Sdefines time in seconds. The relationship is such calories neededdepends on the mass of the receiver and the range of time andtemperature. Preferably temperature range is at least 260° F. and nomore than 440° F. However, it is contemplated that depending on the massof the receiver, different temperature range is needed.

Heating by forced hot air is preferred, although other heat sources,such as infrared heaters, can be used as long as they adequatelypenetrate the fabric to the depth of the ink. In addition to heat, othermechanisms can be used for activating the chemical elements or catalystswithin the donor and setting the dye, which can be determined from thosemechanisms commonly used with particular catalysts, dyes and substratecombinations.

Preferably, heat source is applied continuously onto the donor tosublimate. However, it is contemplated that heat can be indirectlyapplied to the receiver without damaging the receiver. Heat source caneven be applied in short pulse intervals to obtain maximum temperaturewithout prolong exposure. High energy provided in the form of hightemperature for a very short amount of time, breaks the bonds anddisperse the heat on a donor. For example, as a donor sublimates onto areceiver, heat is pulsed only on the side of the donor that is nottouching the receiver. Catalytic conversion of the chemical agents stilloccurs during the pulsing of the heat source even when with higherrising temperature. If the heat is not pulsed at a higher temperature,the receiver can be damaged. Pulsing the heat source allows differentcatalytic phases to occur on the receiver regardless of the donor'sphases. It is another example of the flexibility of the time andtemperature schedule.

Despite a current preference for continuous processing, it is alsocontemplated that embodiments of the inventive subject matter could bepracticed in a discontinuous manner, for example with sandwiched workpieces being assembled, and heat and pressure applied in a piece bypiece manner. In that regard it is specifically contemplated that thereceiver could be cut from a bulk material. There are existing machines(e.g. Monti Antonio™, Practix™ and other cylinder based machines) thatcould be modified to operate according the inventive concepts describedherein.

In preferred embodiments, upon a schedule, the donor materials willeither reacted or formed an affinity with different preparation agents,fabric enhancers, and dyes. It should also be appreciated that the terms“schedule”, “schedules” are used in the broadest possible sense toinclude the specific and discreet time and temperature upon which eithera preparation agent, a fabric enhancer, or dye is activated anddispersed into the fabric. Thus, the terms “schedule” and “schedules”include a range of temperature for a set time frame.

For example, as donor material enters into the process equipment, firstpreparation agent, preferably a bleach, will be activated when upon afirst schedule, when the temperature reaches 290° F. but not more than320° F. for at least 1.8 seconds.

In an alternative embodiment, first preparation bleach is activated uponthe addition a first catalysts and a first schedule. Due to the natureof first catalyst, first schedule preferably includes a highertemperature at a shorter time frame.

Following the activation of the first preparation agent, donor materialconceivably goes through process equipment for the activation of asecond preparation agent at a second schedule. Alternatively, a firstfabric enhancer is activated at the second schedule. For example, afabric softener, calcium hypochlorite, can be activated upon the secondschedule. Second schedule preferably has a temperature of 320° F., whichis higher than first schedule and a time frame of about the same asfirst schedule. A third fabric enhancer is then activated at a thirdschedule, which preferably has a temperature of 345° F. higher thansecond schedule and a time frame of about the same as second schedule.The process repeat itself so forth until all fabric enhancers have beenactivated and dispersed into the fabric.

Preferably, following the activation of all fabric enhancers, a firstdye will be applied to donor material at a fourth, fifth, sixth, etc.schedule for dispersion. It is contemplated that the heating step of theprocess causes the dye particles to change from a solid state to a gasstate. The preferred temperature range for dye particles to enterpreferably is more than 385° F. for at least 2.5 seconds. However, otherrange, such as a temperature of 380° F. to 420° F. for at least 10seconds are also contemplated. As heated dye molecules the now heatedfabric, they exchange places and become part of the fabric filament. Nowthe dye laden molecules are a permanent part of the interior of thefabric and are not affected by normal washing or bleaching.

Receiver 50 can be any material that can receive sublimation printing.This includes most especially polyesters and other synthetic polymersthat absorb dyes at high temperature and pressure, with currentlypreferred receiver materials including the true synthetics ornon-cellulosics (e.g., polyester, nylon, acrylic, modacrylic, andpolyolefin), blends, and so forth. It is contemplated that receivermaterials could also include natural fibers (e.g., cotton, wool, silk,linen, hemp, ramie, and jute), semi-synthetics or cellulosics (e.g.,vicose rayon and cellulose acetate), but currently available colorantsdo not “take” very well with such fibers. Receivers can be flexible orrigid, bleached or unbleached, white or colored, woven, non-woven,knitted or non-knitted, or any combination of these or other factors.Thus, a receiver could, for example, include a woven material on oneside and a non-woven or different woven material on the other side.Among other things, receivers are contemplated to include fabrics andfibers used for clothing, banners, flags, curtains and other wallcoverings, and even carpets.

Tissue 40 can be selected from known take up tissues used in theindustry and is used in the current embodiments to absorb dyes that passentirely through receiver 50 and donor material 30. It also serves inembodiments of the present invention to protect the mechanical partsfrom excess colorant.

The advantages of the methods and systems disclosed herein are enormous.Instead of shipping fabric from site to site and often from country tocountry in preparation for assembly into a final ready-to-wear product,a single process provides for the preparation, the finishing and theprinting and dyeing of fabric. This one-stop shop process not only savesa tremendous amount in costs and time, but also effectively eliminatesmany chemical wastes that accompany traditional textile productionmethods.

By having a discreet time and temperature scheduling for chemicaladditives, the present inventive subject matter overcomes the hurdlesthat blocked a single-pass process method from previous efforts. Besidesproviding a nonpolluting catalysts for activation of a chemicaladditive, a single source energy combined with a discreet applicationand scheduled delivery provide for a even more comprehensive andefficient process to prepare textile. The reduction in time and laborcosts provides an attractive and commercially viable application for thepresent inventive subject matter.

EXAMPLES

The following examples illustrate particularly embodiments of thepresent inventive subject matter, and aid those of skill in the art inunderstanding and practicing the inventive subject matter. They are setforth for explanatory purposes only, and are not to be taken as limitingthe present inventive subject matter in any manner.

Example 1 Chemical Agents

The following are a group of chemical agents that can be used duringsublimation following a predetermined time and discreet temperatureschedule.

Bleach

Typically, for performance based fabric, bleaching is a preferred methodof preparing the fabric. The purpose of bleaching is decolorizenaturally present pigments into whitened fabric that can accept dyeswithout damaging the fabric. Many sources of bleach may be used, such asoxidative bleaches and reductive bleaches. Preferably, oxidativebleaches, such as sodium hypochlorite (NaOCl), calcium hypochlorite(CaCl₂O₂), hydrogen peroxide, persulfates, perboarates and percarbonatesalong with peracetic acid; and reductive bleaches, such as sulfurdioxide and sodium dithionate can be used as bleaching agents.

More preferably, calcium hypochlorite or sodium hypochlorite, are used.Both of which are excellent cidal agents for mildew and other bacteriafound and both can be found commercially. Commercial sodium hypochloritecontains at least 12 to 15% active chlorine and sodium hypochlorite canbe found as a solid material that contains at least 65% active chlorine.

Time and temperature of bleaching are interrelated. As the temperatureincreases, less time is needed to activate the bleaching agent. Higherbleach concentration also requires less time and temperature foractivation. Preferred sources of bleach are used as long as it can beactivated in room temperature or temperature from 280° F. to 320° F. ina preferred time period of 1.8 seconds to 2.2 seconds.

Amount of bleaching agents used depends on the different types andcharacteristics of the fabric. For example, when darker dyes are to beused, fabrics may not necessarily needs to be bleached. Example of apreferred bleaching formulation can be shown in Table 1.

TABLE 1 Bleach Formulation NaOC1 2.5% active bleach Na2CO3 1.0% pHbuffer

Preferably bleaching is performed under a single continuous equipment inwhich the time and temperature are correlated to activate the bleachingagents onto the fabrics.

Other types of bleaches, such as hydrogen peroxide, may require highertemperature to decompose and depending on the other agents used, mayserve as a better bleaching agent in a single continuous sublimationequipment. Sodium chlorite, another bleaching agent, that allows forbleaching at a much higher rate of temperature is also contemplated.

Fabric Softener

Fabric softeners are used to improve the way fabric feels by breakingdown hardness or stiffness. Softeners also improve abrasion resistance,increase tearing strength, reduce sewing thread breakage and reduceneedle cutting when the garment is sewn. Most softeners are divided intothree major chemical categories describing the ionic nature of themolecule, namely anionic, cationic and nonionic. Most softeners are alsobased on fatty acid amine condensates and can be used in a wide range oftime and temperature delivery process.

Preferred softeners are anionic softeners, which exhibits excellentstability under high temperature. Anionic softeners, such as sulfates,sulfonated fatty amides and esters do not interfere with finishes and tobe foamed. Preferred softeners act like defoamers and exhibitsubstantial rewetting prosperities. Fabrics that are treated withsofteners are contemplated to be carried in discreet time andtemperature schedule. Preferred softener are made from the synthesis ofthe fatty acid amide basis and the addition of suitable additives intothe softener formulation, along with the addition of a lubricant thatcan be activated by an acidic catalysts.

Compositions of the softeners can vary depending on the desired effectsand the nature of the fabric being treated. Hydrocarbon radials having atotal of 8 to 20 carbons are the most effective molecular group used intextile softeners. Preferably, a high-class, multifunctional softenersare contemplated, which not only contain emulsified fatty acidcondensates but also different silicones and waxes respectively. Suchcombinations not only allow for distinctly better effects but theproperties of the softeners can be tailor-made to meet the individualrequirement profile.

Many sources of fabric softener may be used as long as it can beactivated in room temperature or temperature from 310° F. to 350° F. ina preferred time period of 2.0 seconds to 2.3 seconds. For example, U.S.Pat. No. 4,185,961 (to Danzik) describes a fabric softener comprises anaqueous solution containing dimethyloldihydroxy ethylene urea (DMDHEU)and an acidic catalyst in column 2, lines 14-21. U.S. Pat. No. 7,108,725(to Caswell) describes a fabric softener comprising a film encapsulatinga water-soluble composition with the composition comprises from about 5%to about 20%, by weight of the composition, of a polydimethyl siloxaneor derivative thereof in column 61, lines 52 to 67 and column 62, lines1 to 45.

Nonionic softeners, such as silicones, ethylene oxide derivatives, andhydrocarbon waxes based on paraffin or polyethylene are alsocontemplated. Silicones, for example, are water clear oils that arestable to high temperature and do not discolor fabric.

Repellent Agents

Many sources of repellent agents can be used. Stain repellent treatsfabric to withstand penetration of liquid soil under static conditionsinvolving only the weight of the drop and capillary forces. Oilrepellent agents resists oil from residing on top of the fabric and stopit from penetrating to the fabric surface. Water repellent agentsactivates pores on fabric surfaces to permeate air and water vapor,unlike water proofing agents, which blocks the penetration of waterunder higher hydrostatic pressure.

For fabrics to be water repellent, the critical surface tension of thefiber's surface must be lowered to about 25 to 30 dynes/cm. Oilrepellency requires that the fiber surface be lowered to 13 dynes/cm.Preferred sources of repellent agents include fluorocarbon finishes.Fluorochemical polymers prevent oils from penetrating into the fabricsor prevent soils ticking to the fiber surface. Most fabric stains arecaused by liquids depositing coloring matter on the fabric. For textilesthat cannot be laundered, e.g. upholstery fabrics and carpets,fluorochemical finishes provides a more efficient and effective deliveryfor stain and soil repellency. A typical formulation is shown in Table2. The finish can be applied by padding the formulation onto the fabricthrough a single process sublimation unit at a temperature of at least330° F. to 370° F. for least 2.2 seconds to 2.4 seconds. Drying cyclesis accomplished by super heating the fabric for the next step in theadditive delivery schedule.

TABLE 2 Fluorochemical Repellent Formulation Agents % Bath ConcentrationFluorochemical product  2.0-3.0 Resin wax water repellent  2.0-3.0DMDHEU   10-15 MgCl2 catalyst  2.5-4.0 Polyethylene softener  0.5-2.0Non-wetting surfactant 0.03-0.05 Acetic acid 0.05-0.1

Other types of repellent agents such as, paraffin waxes, hydrocarbonbased hydrophobes, N-methylol stearamide, pyridinium compounds, resinformers, and even silicones are contemplated. Repellent agents areapplied as an organic solvent.

Stain Release Agents

Stain release agents conditions the fabrics to block out the tougherparticles and soils that can penetrate the fabric. Most stain releaseagents are nonionic, for example, the nonionic stain release polymerdescribed in U.S. Pat. No. 4,849,257 (to Borcher, Sr., et al.),abstract, which is incorporated herein by reference. Preferred stainrelease agents is a polymeric agent that includes copolymeric units ofrepeating units of ethylene and/or propylene groups. Fluorochemicalpolymers are such nonionic soil release agent that provides excellentdual action for oil and stain release. For example, Scotchgard BrandDual-Action Fabric Protector, a unique block co-polymer, developed by 3MCompany provides dual action clean. The hybrid polymer backbone iscomprised of segments based on polyoxyethylene united with segmentscontaining long-chain perfluoroaliphatic groups.

Other useful stain release agents can include anionic and cationicpolymers. Suitable anionic polymeric or oligomeric soil release agentsare disclosed in U.S. Pat. No. 4,018,569 (to Chang), column 3, lines25-50, which is incorporated herein by reference. Other suitablepolymers are disclosed in U.S. Pat. No. 4,808,086 (to Evans et al.),column 2, lines 45-55, which is incorporated herein by reference.

The finish preferably can be applied by padding the formulation onto thefabric through a single process sublimation unit at a temperature of atleast 330° F. to 370° F. for least 2.2 seconds to 2.4 seconds.

Antimicrobial Agents

Antimicrobial agents alter the characteristics of fabric surface toprevent penetration of microbial or bacterial agents from entering thefabric. Preferred sources of antimicrobial agents include highperformances agents that contain silver ions, such as silver oxide, anexcellent antimicrobial agent. Exhibiting a polar charge, the silvergenerates an ion field on the surface of the fabric and the bacteriaexchange ions with the silver oxide upon contact with the fabric, inturn ripping open their cell walls and killing them. U.S. Pat. No.6,436,420 (to Antelman et al.) describes a high performance silverantimicrobial agent that is a suitable source.

Other non-silver sources are also contemplated. U.S. Pat. No. 5,271,952(to Liang et al.), abstract, U.S. Pat. Nos. 4,410,593 to (to Tombie etal.), abstract and 5,458,906 (to Liang), abstract, all disclose copperions as a suitable source of anti-microbial agents. Recent technologyallows nanopolymers to be encapsulated onto the surface of fabric forgreater penetration and dispersion, such as the one described in thedetailed description of U.S. Pat. No. 7,112,621 (to Rohrbaugh). Finally,U.S. Pat. No. 6,251,210 (to Bullock et al.), column 4, lines 33-50,describes a method of preparing a stain resistant, water repellent andanti-microbial agents textile fabric. All these references herein areincorporated in their entirety.

Similarly, anti-microbial agents preferably can be applied by paddingthe formulation onto the fabric through a single process sublimationunit at a temperature of at least 330° F. to 370° F. for least 2.2seconds to 2.4 seconds.

Adhesive Agents

Adhesive agents is preferably applied for flocking. Flocking is a methodof cloth ornamentation in which finely chopped fibers are applied toadhesive coated surfaces. The majority of flocking uses finely cutnatural or synthetic fibers. In the flocking process, the fabricsubstrate is first coated with an adhesive, followed by applying fine ormonofilament fibers (usually nylon, rayon or polyester) and dried. Theflocked finish imparts a decorative and/or functional characteristics tothe surface, such as school initials or emblems.

The diameter of the individual strand preferably is a few thousandths ofa centimeter and ranges in length from 0.25 mm to 5 mm. Preferredembodiments first applies a layer of adhesive onto the donor substrate,followed by a quick dry at a high temperature. This removes moisturefrom the adhesive, but still leaves the crystalline properties of theadhesive. Then the flock fibers are applied and upon release, theadhesion creates a low tensile strength that would allow the fibers tobe vertical and stand up to create the flocking effect.

Flock can be natural or synthetic materials, such as cotton, rayon,nylon and polyester. Preferred types of flock is cut flock, which isproduced from quality filament synthetic materials. The cutting processproduces a very uniform length of flock. Preferred lengths of the flockrange from 0.3 mm to 0.5 mm and 1.7-22 dtex in diameter. However, milledflock, which is produced from cotton or synthetic textile waste materialis also contemplated.

A variety of adhesives can be used for flocking purposes. In general,flock adhesives are in both a single a two-part catalyzed system.Preferred adhesive can be either plastisol or water-based adhesives andhave the consistency of plastisol ink.

Dyes and Colorants

Preferred dyes and colorants for use in the present compositions includehighly water-soluble dyes, for example, LIQUITINT dyes available fromMilliken Chemical Company. Any dye can be used in the compositions ofthe present invention, but nonionic dyes are preferred to decreaseinteraction with the zeta potential modifier and/or with the dyetransfer inhibitor employed in combination with the inventivecompositions.

Suitable colors include, but are not limited to, Acid Black 1, Acid Blue3, Acid Blue 9 Aluminum Lake, Acid Blue 74, Acid Green 1, Acid Orange 6,Acid Red 14 Aluminum Lake, Acid Red 27, Acid Red 27 Aluminum Lake, AcidRed 51, Acid Violet 9, Acid Yellow 3, Acid Yellow 3 Aluminum Lake, AcidYellow 73, Aluminum Powder, Basic Blue 6, Basic Yellow 11, Carotene,Brilliant Black 1, Bromocresol Green, Chromium Oxide Greens, Curry Red,D&C Blue No. 1 Aluminum Lake, D&C Blue No. 4, D&C Brown No. 1, D&C GreenNo. 3 Aluminum Lake, D&C Green No. 5, D&C Orange No. 4 Aluminum Lake,D&C Red No. 6, D&C Red No. 6 Aluminum Lake, D&C Violet No. 2, D&C YellowNo. 7, D&C Yellow No. 11, D&C Blue No. 1, FD&C Yellow No. 5 AluminumLake, iron oxides, Pigment Orange 5, Pigment Red 83, Pigment Yellow 73,Solvent Orange 1, Solvent Yellow 18, ultramarines, and zinc stearate.

Example 2 Single Pass Additive Scheduling

One embodiment of the present inventive subject matter is thesublimation of a donor material that includes the activation of ableaching agent, an anti-microbial agent, a stain-release agent,followed by the printing and dyeing of the donor.

The scheduled release and bonding of each of the stacked chemical agentis completed based on a temperature defined time window. The chemicalagents are applied as either a layer or component of a donor substrate.Once the donor has been placed in contact with the target object(usually fabric) heat is applied to the combination (donor and object).At lower temperatures both remain inert, but as the temperature of thecombination rises it triggers a catalytic phase change in each of thefabric enhancer previous to the dyeing and or printing of the objectdonor in the same machine. FIG. 2 illustrates the time and temperaturerelease of the chemical elements.

Under room temperature, a donor with special dyes and prints has beenconditioned with a bleaching agent, calcium hypochlorite inconcentration of 1:20; silver oxide, an anti-microbial agent, inconcentration of 1:50; and Scotchgard, a stain release agent prior tosublimation.

Once the donor is treated, it goes through a single-pass sublimationmachinery starting with preheating at a optimal temperature of 260° F.The sublimation process starts at point A and the donor remains inertdue to the low temperature and short amount of sublimation time. As thedonor material continues to sublimate at a temperature of 290° F. foraround 1.80 seconds at point B1, calcium hypochlorite, the bleachingagent, is activated. Immediately following the activation of thebleaching agent, the donor material proceeds further through the singlepass machine and the anti-microbial agents are activated at 330° F. for2.0 seconds at point B2. Next, the stain release agent is activated at aeven higher temperature of 365° F. for a total sublimation time of 2.25seconds at point B3. Then without interruption, the sublimation singlepass machines sublimates the donor onto the receiver, a fabric fordyeing and printing stage in the single pass machine at a temperature of385° F. for a total of 2.5 seconds at point C. The entire sublimationprocess can be finished in less than one minute with a continuousseamless process without any environmental impact.

Thus, specific embodiments and applications of a time and temperatureadditives scheduling have been disclosed. It should be apparent,however, to those skilled in the art that many more modificationsbesides those already described are possible without departing from theinventive concepts herein. The inventive subject matter, therefore, isnot to be restricted except in the spirit of the appended claims.Moreover, in interpreting both the specification and the claims, allterms should be interpreted in the broadest possible manner consistentwith the context. In particular, the terms “comprises” and “comprising”should be interpreted as referring to elements, components, or steps ina non-exclusive manner, indicating that the referenced elements,components, or steps may be present, or utilized, or combined with otherelements, components, or steps that are not expressly referenced. Wherethe specification claims refers to at least one of something selectedfrom the group consisting of A, B, C . . . and N, the text should beinterpreted as requiring only one element from the group, not A plus N,or B plus N, etc.

1. A sublimation donor, comprising a first fabric enhancer thatsublimates from the donor above a first temperature, and a second fabricenhancer that sublimates from the donor above a second temperature,wherein the first and second temperatures are each above 260° F., andwherein the second temperature is at least 10° F. higher than the firsttemperature.
 2. The donor of claim 1, further comprising first andsecond catalysts that trigger the first and second fabric enhancers tosublimate at the first and second temperatures, respectively.
 3. Thedonor of claim 2, wherein at least one of the catalysts is selected fromthe group consisting of olefins, sulfonium compounds, polyanilinecompounds, and tetra-amido macrocyclic ligands.
 4. The donor of claim 1,wherein the fabric enhancer is a finishing agent.
 5. The donor of claim1, wherein the fabric enhancer is a conditioning agent.
 6. The donor ofclaim 1, wherein at least one of the fabric enhancers comprises ofbleach.
 7. The donor of claim 1, wherein at least one of the fabricenhancers comprises an antimicrobial substance.
 8. The donor of claim 1,wherein at least one of the fabric enhancers comprises a stain releaseagent.
 9. The donor of claim 1, wherein the first and second fabricenhancers are selected from the group consisting of bleach, anantimicrobial substance, and a stain release agent.
 10. The donor ofclaim 1, wherein the first and second temperatures differ by at least20° F.
 11. The donor of claim 1, wherein the first and secondtemperatures differ by at least 30° F.
 12. The donor of claim 1, furthercomprising first and second different colorants, each of whichsublimates from the donor at a temperature of at least 360° F.
 13. Afabric produced using the sublimation donor of claim 12, wherein thefabric contains visually detectable amounts of both first and secondcolorants, the fabric further contains a detectable amount of the firstfabric enhancer, and the first fabric enhancer is selected from ableach, an antimicrobial substance, and a stain release agent.
 14. Thefabric of claim 13, wherein the first and second colorants aresublimated onto the fabric in a continuous disposition.
 15. The fabricof claim 13, wherein the fabric contains a detectable amount of thesecond fabric enhancer, and wherein each of the first and second fabricenhancers is selected from a bleach, an antimicrobial substance, and astain release agent.
 16. A receiver, comprising a first fabric enhancerthat activates to the receiver above a first temperature, and a secondfabric enhancer that activates to the receiver above a secondtemperature, wherein the first and second temperatures are each above260° F., and wherein the second temperature is at least 10° F. higherthan the first temperature.